Process and apparatus for the manufacture of frozen desserts

ABSTRACT

Italian Cassatas are manufactured by positioning topless polygonal containers having separable bottoms in holes in a rotating turret which positions them successively beneath a plurality of stations, each of which introduces a different type of ice cream. The filled containers are then frozen, the separable bottoms removed, and the containers filled with ice cream cut into triangular segments by pushing them downwardly through a set of cutting blades.

United States Patent 1191 Marchi Dec. 11, 1973 [5 PROCESS AND APPARATUSFOR THE 2,976,155 3/1961 Heller 1 99/137 MANUFACTURE OF FROZEN DESSERTS2,027,255 1/1936 V ogt et al....... 62/320 3,085,520 4/1963 F1edlgr62/320 Inventor: Anton") Marchl, Parma, Italy 1,719,931 7/1929 11311425/328 [73] Assignee: Foodice Engineering ltaliana S.p.A.,

Pafma, ltaly Primary Examiner-William E. Wayner [22] Filed; July 26,1972 Assistant Examiner-William E. 'll'apolcai Attorney-Joseph F.Bnsebors et al. [21] Appl. No.: 275,266

[30] Foreign Application Priority Data ABSTRACT I 1, ltaly ItalianCassatas are manufactured positioning p less polygonal containers havingseparable bottoms in [52] gig g g g holes in a rotating turret whichpositions them succes I t Cl 7" sively beneath a plurality of stations,each of which ing 130 troduces a different type of ice cream. The filledcong g g $55531 141; 4 tainers are then frozen, the separable bottomsremoved, and the containers filled with ice cream cut References Cited1nto tnangular segments by pushing them downwardly through a set ofcutting blades.

12 Claims, 9 Drawing Figures PATENI untm 1 ma SHEET 5 [IF 6 PAINTEnuEc11 1915 saw s [1F 5 1 1 PROCESS AND APPARATUS FOR THE MANUFACTURE OFFROZEN DESSERTS SUMMARY OF THE INVENTION The frozen dessert of theITALIAN CASATTA type is in the form of a prism of triangularcrosssection, which rests on one of its lateral surfaces and consists oflayers of different materials, substantially superimposed one on theother, composed of ice cream of different flavors with or without theincorporation of crystallized fruits.

Thesecharacteristics of the cassata have heretofore excluded thepossibility of manufacturing it by automatic processes enabling highproduction rates to be obtained, particularly because of the need toform the individual pieces manually.

The object of the present invention is to make available a process forthe production of cassatas which may be carried out mechanically andautomatically while allowing the product to retain its particularcharacteristics of shape and content.

A further object of the present invention is to make available suitableapparatus for carrying out said process mechanically and automatically.

According to the invention, the process for the formation of cassatascomprises the following steps:

a. positioning on an aluminum base a container in the form of aparallelepiped or prism of regular polygonal cross-section open at atleast its upper end and made of suitable waterproofed cardboard or othersuitable material;

I b. positioning thisaluminum base and container on a rotating turret;

c. bringing the container successively beneath at least three fillernozzles adapted to introduce three types of ice cream into the upwardlyopen container;

d. rotating the container about its own axis if so desired, duringfilling, so that the quantities of ice cream are arranged in threeconcentric layers;

e. inserting the filled container and base into a freezing tunnel and/orsuitable freezing cells to bring the entire creamy mass to a temperatureof at least C below zero;

'f. removing the aluminum base, after warming it,

from the cardboard container;

g. subjecting the container full of ice cream to the action of a hollowpunch for separating itinto as many triangular segments as there aresides of the regular polygon defined by the cross-section of thecardboard container.

In this manner cassatas are obtained having the classical prismatictriangular form with a resting base of impermeabilized cardboard, orother suitable material,

and are composed of at least three superimposed nonintermixed layers ofdifferent types of ice cream, with or without the inclusion of pieces ofcrystallized fruit. From the foregoing description it can be deducedthat the means for mechanically carrying out the process comprise twoseparate units, in addition to the consumed cardboard container and thealuminum base; namely a fillingmachine and a cutting machine.

Between these two machines, which characterize the apparatus accordingto the present invention, is the cooling means, in the form of a tunnelor cells, or both a conventional type and available in all ice creammanufacturing concerns.

The merits and functional and constructional characteristics of theinvention will be more evident from the detailed description givenhereinafter with reference to the accompanying drawings, and having asits object a particular preferred embodiment of the invention givenpurely by way of illustration and example.

The apparatus and process will be described simultaneously, to theadvantage of the simplicity and clarity of the description.

FIG. 1 is a diagrammatic plan view ofthe layout of the entire apparatusfor carrying out the process of the invention.

FIG. 2 is a partly sectional perspective view of the filling machine.

FIG. 3 is a vertical section through a delivery assembly of the fillingmachine.

FIG. 4 is a vertical section though the separating or cutting machine.

FIG. 5 is an enlarged perspective partially sectional view of thecutting assembly of the cutting machine.

FIG. 6 is a fragmentary view taken in the direction VI shown in FIG. 9.

FIG. 7 is a fragmentary view taken in the direction VII shown in FIG. 6.

FIG. 8 is an enlarged vertical section taken through the working part ofthe cutting machine.

FIG. 9 is a diagrammatic plan view of the cutting machine.

The figures show the box casing (A) of waterproof cardboard,open at itsends and closed at its bottom by the base (B) of the aluminum. Thiscasing is filled with ice cream at the machine (C), is then passed tothe cooling means (D). The base (B) is then removed at the machine (E)and at the outlet of the latter the product emerges dividedinto foursegments, each constituting a cassata.

Filling takes placeat the machine (C) shown in FIGS. 2 and 3.

This machine comprises a base 1 containing an electric motor 2,preferably of the self-braking type, coupled at a speed reducer 3. Theoutput shaft of the latter drives through a belt 4 a worm 5 whichengages a pinion 6. A pin 7 carried by the pinion 6 cooperates with thewheel 8 to form a Maltese cross coupling. The shaft 9 to which is keyedthe wheel 8 projects upwardly from the base 1 and is supported axiallyby the support 10.

This shaft 9 moveswith intermittent motion and supports a plate 1 l inwhich are formed peripheral seats 12 adapted to exactly contain thecontainer (A) and its relative base (B).

The feeding of the containers to the plate 11 and their removal from itmay be carried out by suitable conveyor belts not shown in the figure.

In particular the full containers are unloaded from the plate 11 ontothe conveyor belt by the ejector 13 operated by the cylinder-pistonassembly 14. From the base 1 three columns 15 branch upward, each ofwhich supports a feed assembly 16 of the type shown in FIG. 3.

It is evident that. said feed assemblies are spaced apart the samedistance as the distance between the seats 12, so thatduring-intermittent motion of the plate 11 each seatstopsunder each ofthe assemblies 16.

Each of the feed assemblies 16 comprises a box 17 supported by thecolumn 15, and on which is housed a pneumatic cylinder-piston assembly18. The rod 19 of this latter engages one end of a lever 20, pivotallyattached at 21 to the lateral walls of the box 17. The opposite endofthe lever is connected by the connecting rods 22 to afork-shaped slide23, guided by the rods 24. The slide 23 embraces the tube 25, housingthe rod 26. The tube 25 is axially slidable with respect to the box 17guided by the lower body 27 and upper body 28. The body 28 extendsupwards in the form of the cylindrical tube 29.

The rod 26 is axially slidable within the tube 25 and is biaseddownward, with relation to the tube, by the spring 30.

This latter acts between the cap 31, screwed to the top of the tube 25,and the shoulder 32 on the rod 26.

The part of the rod 26 which projects above the tube 25 carries screwedthereto the cup-shaped body 33, which is locked in the desired positionby the threaded knob 34, which acts as a locking nut.

' The part of the rod 26 which projects below the tube 25 carries apiston 35 and a plug 36.

These are located in the cylinder 37 which is rigidly attached to thetube 25, and to the bottom of which is screwed the delivery nozzle 38.

To the lateral wall of the cylinder 37 is connected the tube 39 whichfeeds the ice cream from suitable pressurized feeders connectedupstream.

Entry of the cream into the cylinder is prevented by the piston 35, andis possible only when the piston is raised with respect to the cylinder.

The rod 19 of the cylinder piston assembly 18 also actuates the rod 40,which slides in the guide 41 fixed to the box 17. The rod is urgedupward by the spring 42. The lower end of the rod 40 is pivoted to thelever 43, which turns about the pivot pin 44 and carries at its oppositeend the two sections 45 which hold the container (A) still while it isbeing filled.

The operation of the feed assembly heretofore described is believedobvious:

During the stationary periods of the plate 11, the rod 19 is raised andthe assembly comprising the tube 25, rod 26 and sections 45 is loweredfor a certain distance. When the cup body 33 rests against thecylindrical tube 29, the descent of the rod ceases and the tube 25continues to descend alone. The descent of the sections 45 ceases whenthey rest on the edge of the container (A). The successive descent ofthe tube 25 with respect to the stationary rod 26 causes opening of theinlet port of the tube 39 for feeding the ice cream, and this flows outthrough the nozzle 38. The return of the rod 19 to its original positionrestores the closed conditions.

The containers (A), filled during their successive stops under the threedelivery units 16, are then removed from the plate 11 by the ejector 13and fed to the cooling assemblies (D), consisting partly of a tunnel andpartly of freezing cells.

After a convenient length of time, necessary for causing the homogeneoushardness of the entire mass, the containers (A) full of ice cream, andprovided with the aluminum base (B), are fed to the machine (E) forcutting the cassatas.

This machine, with particular reference to FIGS. 4 to 9 comprises a feedassembly upstream of the actual cutting assembly.

The feed assembly (see FIG. 9) comprises a base 46 supporting a conveyor47 driven with continuous motion by a motor, not shown, and having awidth equal to the height of the containers (A), which are arranged onit downward with their open ends to the sides. Adjacent the base 46 is aheated surface 48 provided with two dovetail guides 49. The containers(A) rest on the surface 48 while lying on their aluminum base (B), sothat the separation of their base by engaging its edge under one of thetwo guides 49 is facilitated.

The conveyor 47 is at the same level as the loading station of thecutting assembly.

This latter comprises a base 50 within which an electric motor 51 drivesa wheel 43 carrying an eccentric pin 54 through the chain drive 52.

The wheel 53 is rigidly attached to a gear wheel 55 of greater diameter,contained in the box 56. v

The gear wheel 55 engages the wheel 57, which is rigidly attached to abevel gear 58, which forms with the gear 59 right angle transmission.The gear 59 is mounted to the vertical shaft 60 which supports the disc61 provided with the eccentric pin 62. This latter forms with the wheel63 a Maltese cross mechanism which imparts an intermittent motion to thewheel 63.

This latter is keyed to a vertical shaft 64, which projects upwardlyfrom the base and supports a disc 65 which comprises the same number ofperipheral apertures 66 as there are peripheral cavities in the Maltesewheel, each peripheral aperture 66 passing completely through the disc65. Beneath one half of the disc 65 is an inclined surface 67 locatedsome distance from the disc at the loading station, and at a minimumdistance from the disc immediately upstream of the cutting station. Onthis surface the containers which are inserted into the aperture 66 aresupported upright. The loading station, situated at the same level asthe conveyor 47, comprises a box housing 68, which in the raisedposition has two open sides, namely the side overlooking the conveyor 47and one of the adjacent sides. The housing 68 is located following thebelt 47 and into it flow one at a time the containers (A) full ofhardened ice cream.

At its lower edge opposite its open side the housing 68 comprises hinges69 mounted on the pivot pin 70 which extends horizontally from the plate71 fixed to the base 50. Rigid with the housing 68 and coaxial with thepivoting system 67-70 is a pinion 72 engaging the straight track 73 sothat the traverse motion imposed on this latter by the cylinder-pistonassembly 74 results in 90 rotations of the housing 68.

During these rotations the housing 68 drops the container (A) into theunderlying aperture 66 in the disc 65, resting it on the inclinedsurface 67.

The housing 68 comprises a cap 75 operated by the cylinder-pistonassembly 76 and adapted to clamp the container (A) within the housing68.

Below the disc 65 in a position diametrically opposite to that of thehousing 68 is a chamber 77 which reproduces in plan view the dimensionsof the container (A). In particular the chamber 77 is placed immediatelybeyond the surface 67 so that the containers (A), drawn by the disc 65until they leave the suface 67, fall into it upright. Inside the chamber77 are four fixed blades 78, positioned along the diagonals of thechamber, and

these divide the container (A) into four segments which fall onto theunderlying belt conveyor 79.

The container (A) is forced to pass through the blades by an upperplunger 80 which comprises four slots 81 which receive the blades.

In order to facilitate removal of the block of ice cream from theplunger 80, there is a pusher 82 at right angles thereto and under theblades which is operated by a cylindenpiston assembly 83.

The plunger 80 is at the end of the rod 84 which oscillated by therocker arm 85 pivoted at 86, and the connecting rod 87 derived from theeccentric pin 54. The segments of the container (A) each constitute acassata which is removed by the belt 79, and fed to the packagingdevices situated downstream.

The invention is not limited to the embodiments hereinbefore described,and modifications and improvements thereof may be made without departingfrom the scope of the invention, the fundamental characteristics ofwhich are summarized in the following claims.

I claim:

1. Process for the mechanical production of frozen desserts known asITALIAN CASSATA comprising the following steps:

a. positioning a container having two open ends and a regular polygonalcross-section on a separable base;

b. positioning said base and container on a rotating turret;

c. rotating said turret to bring said container successively beneath atleast three filler nozzles adapted to introduce three types of ice creaminto said container;

d. introducing said container and base into freezing means which bringsit to a temperature at least C below zero;

e. removing said base, and

f. slicing the container full of ice cream into as many triangularsegments as there are sides of the regular,

polygon defined by the cross-section of the container.

2. Apparatus for producing frozen desserts known as ITALIAN CASSATA,said apparatus comprising a rotatable turret adapted to bring containershaving a polygonal cross-section and a separable metal base successivelyinto each of a plurality of stations, said stations comprisingsucessively means for introducing into said container a different typeof ice cream; freezing means for uniformly hardening the cream in thecontainer; heating means for heating said base to facilitate itsseparation and removal from said container, and means for cutting thefilled container into segments after removal of said base.

3. Apparatus as claimed in claim 2 in which each filling stationcomprises a column, a support box mounted on said column for adjustmentupward and downward, said box comprising two vertically aligned seats, atube axially slidable in said seats and containing an axially slidablerod projecting from the top of the tube and carrying a stop member, apiston projecting downwardly from the tube, said tube terminating at itslower end in a cylindrical body provided with a lower nozzle andcontaining the piston, a feed tube for the ice cream under pressureprojecting from the wall of said cylindrical body and so positioned thatits inlet port into said cylindrical body is opened and closed by thepiston, means in the box for causing simultaneous lowering of both theaxially slidable tube and rod and successive lowering of the axiallyslidable tube only with respect to the rod to open the port for theintroduction of ice cream into the cylindrical body.

4. A machine as claimed in claim 3 comprising a spring between the tubeand rod which biasses the rod downward with respect to the tube.

5. A machine as claimed in claim 3, comprising a cylinder-pistonassembly having a rod which extends into the support box and operates arocker arm which causes vertical sliding of a slide member connected tothe tube.

6. A machine as claimed in claim 3 in which the stop member attached tothe rod rests, during the descent of the tube and rod, against a stoprigid with the box.

7. A machine as claimed in claim 2 which comprises feed means adapted topick up said container, while lying on one of its sides from a beltconveyor and to place it upright within a hole in an intermittentlyrotat ing disc above a support surface which lies beneath one half ofsaid disc and which extends to a position diametrically opposite that ofthe feed means, and a cutting device positioned at the end of thesupport surface, said cutting device comprising a chamber having avertical axis and substantially the same cross-section as the container,four transverse blades in said chamber which extend from its centertoward its corners, and a vertical plunger intermittently driven to pushthe container through the blades, and provided with suitable slots intowhich said blades enter.

8. A machine as claimed in claim 7, in which the feed means comprises abox situated in alignment with a belt conveyor, said box being open ontwo adjacent vertical sides, and pivoted parallel to one of these sidesat one of its lower edges, so as to be able to swing a container full ofice cream through 90 into one of the openings in the underlying disc.

9. A machine as claimed in claim 8, in which the box fixed to a pinioncoaxial with the pivot, which pinion meshes with a rack which slidesaxially in suitable guides and is connected to a cylinder pistonassembly, sothat linear movement of the rack is transformed intorotation of the box housing.

10. A machine as claimed in claim 8, in which top of the box carries acylinder piston assembly comprising a rod which extends into the boxitself and supports a cap for clamping the container.

11. A machine as claimed in claim 7, in which the support surfacesituated below the disc is inclined with respect to the disc so as tolie at a maximum distance from it just less than the height of thecontainers at the feed device, and at a minimum substantially zero,distance from it at a diametrically opposite position immediatelyupstream of the cutting chamber. I

12. A machine as claimed in claim 7, comprising an electric motorconnected by suitable speed reduction means both to the drive element ofMaltese cross gearing which drives the upper disc with intermittentmotion, and to a crank mechanism whose connecting rod transmits itsmotion to the vertical pusher through a suitable rocker arm.

l l6 l

1. Process for the mechanical production of frozen desserts known as''''ITALIAN CASSATA'''' comprising the following steps: a. positioning acontainer having two open ends and a regular polygonal cross-section ona separable base; b. positioning said base and container on a rotatingturret; c. rotating said turret to bring said container successivelybeneath at least three filler nozzles adapted to introduce three typesof ice cream into said container; d. introducing said container and baseinto freezing means which brings it to a temperature at least 20* Cbelow zero; e. removing said base, and f. slicing the container full ofice cream into as many triangular segments as there are sides of theregular polygon defined by the cross-section of the container. 2.Apparatus for producing frozen desserts known as ''''ITALIANCASSATA,'''' saId apparatus comprising a rotatable turret adapted tobring containers having a polygonal cross-section and a separable metalbase successively into each of a plurality of stations, said stationscomprising sucessively means for introducing into said container adifferent type of ice cream; freezing means for uniformly hardening thecream in the container; heating means for heating said base tofacilitate its separation and removal from said container, and means forcutting the filled container into segments after removal of said base.3. Apparatus as claimed in claim 2 in which each filling stationcomprises a column, a support box mounted on said column for adjustmentupward and downward, said box comprising two vertically aligned seats, atube axially slidable in said seats and containing an axially slidablerod projecting from the top of the tube and carrying a stop member, apiston projecting downwardly from the tube, said tube terminating at itslower end in a cylindrical body provided with a lower nozzle andcontaining the piston, a feed tube for the ice cream under pressureprojecting from the wall of said cylindrical body and so positioned thatits inlet port into said cylindrical body is opened and closed by thepiston, means in the box for causing simultaneous lowering of both theaxially slidable tube and rod and successive lowering of the axiallyslidable tube only with respect to the rod to open the port for theintroduction of ice cream into the cylindrical body.
 4. A machine asclaimed in claim 3 comprising a spring between the tube and rod whichbiasses the rod downward with respect to the tube.
 5. A machine asclaimed in claim 3, comprising a cylinder-piston assembly having a rodwhich extends into the support box and operates a rocker arm whichcauses vertical sliding of a slide member connected to the tube.
 6. Amachine as claimed in claim 3 in which the stop member attached to therod rests, during the descent of the tube and rod, against a stop rigidwith the box.
 7. A machine as claimed in claim 2 which comprises feedmeans adapted to pick up said container, while lying on one of its sidesfrom a belt conveyor and to place it upright within a hole in anintermittently rotating disc above a support surface which lies beneathone half of said disc and which extends to a position diametricallyopposite that of the feed means, and a cutting device positioned at theend of the support surface, said cutting device comprising a chamberhaving a vertical axis and substantially the same cross-section as thecontainer, four transverse blades in said chamber which extend from itscenter toward its corners, and a vertical plunger intermittently drivento push the container through the blades, and provided with suitableslots into which said blades enter.
 8. A machine as claimed in claim 7,in which the feed means comprises a box situated in alignment with abelt conveyor, said box being open on two adjacent vertical sides, andpivoted parallel to one of these sides at one of its lower edges, so asto be able to swing a container full of ice cream through 90* into oneof the openings in the underlying disc.
 9. A machine as claimed in claim8, in which the box fixed to a pinion coaxial with the pivot, whichpinion meshes with a rack which slides axially in suitable guides and isconnected to a cylinder piston assembly, so that linear movement of therack is transformed into rotation of the box housing.
 10. A machine asclaimed in claim 8, in which top of the box carries a cylinder pistonassembly comprising a rod which extends into the box itself and supportsa cap for clamping the container.
 11. A machine as claimed in claim 7,in which the support surface situated below the disc is inclined withrespect to the disc so as to lie at a maximum distance from it just lessthan the height of the containers at the feed device, and at a minimumsubstantially zero, distance from it at a diametrically oppositeposition immediately upstrEam of the cutting chamber.
 12. A machine asclaimed in claim 7, comprising an electric motor connected by suitablespeed reduction means both to the drive element of ''''Maltese cross''''gearing which drives the upper disc with intermittent motion, and to acrank mechanism whose connecting rod transmits its motion to thevertical pusher through a suitable rocker arm.